Method and apparatus for changing rolls on an embosser/laminator machine

ABSTRACT

An embosser/laminator machine has an adhesive unit releasably connectable with a main frame structure of the machine, and a roll extractor configured to move a roll between the main frame structure and an exchange position between the main frame structure and the adhesive unit when the adhesive unit is spaced from the main frame structure during removal and installation of the roll. The sub-frame comprising the adhesive unit may be formed with a bearing cap that cooperates with the main frame structure such that when the adhesive unit is connected with the main frame structure, the roll is operatively secured to the machine between main frame structure and the sub-frame of the adhesive unit for normal operation of the machine. When the sub-frame comprising the adhesive unit is released and spaced from main frame structure, the roll may be removed from and installed into the main frame structure.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of Ser. No. 15/848,595,filed Dec. 20, 2017, which claims the benefit of provisional applicationof U.S. Ser. No. 62/438,715, filed Dec. 23, 2016, the disclosures ofwhich are incorporated by reference herein.

BACKGROUND

In the production of cellulose ply products, such as toilet rolls,kitchen rolls, paper handkerchiefs, napkins, and similar items, it isfrequent to process a ply of web material by means of embossing, passingthe ply through an embossing nip station formed by a pair of steel rollsor by a pair comprised of a steel roll made of steel or other relativelystiff material, and a pressure roll coated with an elastic material suchas rubber. The steel roll has protuberances that deform the elasticcoating of the pressure roll. The pressure exerted between the embossingroll and the pressure roll causes permanent deformation of the cellulosematerial ply, which passes through the embossing nip formed between theembossing roll and the pressure roll. Two or more plies, at least one,some or all of which are embossed, are then brought together to form amulti-ply web material. The web material may be wound to form rolls, orit can be cut and folded to form handkerchiefs, napkins, or similar.Each ply may in turn consist of one or more layers of cellulosematerial.

The embossing pattern is for decorative and functional purposes. From afunctional point of view, embossing serves to create limited areas towhich glue is applied to bond multiple plies that form the web materialto one another. Embossing is also used to increase the overall thicknessof the web material, increase its softness and absorption capabilities,and for other functions known in the field.

An embossing-laminating device is generally defined as a device thatperforms an embossing process on at least one ply and bonds two or moreplies together by lamination, possibly using glue applied to at leastone of said plies, preferably on the protruding surfaces of at leastsome of the embossing protuberances formed on one or more plies.

To meet the needs of modern tissue paper converting lines, the embossingrolls of the embossing/laminating device need to be changed, both inorder to aesthetically change the pattern of the web material, and inorder to change its functional characteristics; for example, to switchfrom the production of toilet paper to the production of kitchen paperand vice-versa. Indeed, since embossing in certain cases has functionaluses that are not simply aesthetic, embossing patterns used to producetoilet paper are not always suitable for the production of kitchenpaper, and vice-versa. The consistency, thickness, weight and content ofcellulose plies for the production of various types of finished articlesmay also differ, requiring embossing patterns which differ from one typeof product to another.

Embossing/laminating machines have been designed that have particularfeatures aimed at simplifying and speeding up the embossing rollchange-over process.

EP1074382 discloses an embossing-laminating device wherein a set ofthree embossing rolls is mounted on a star rotating unit, which makes itpossible to select one or other of the three embossing rolls to make itco-act with the pressure roll, so as to modify the embossing pattern.Depending on the type of pattern required, one or other of the threerolls is brought to the operating position by rotating the star unit. Insome embodiments disclosed in EP 1074382, the star rotating unitsupports three pairs of embossing rolls which can be selectively broughtto the operating position, to co-act with two pressure rolls, byrotating the star unit.

This known device is particularly complex and requires a heavy supportstructure for the embossing rolls, which all remain supported by thesame star unit that supports the pair of embossing rolls actually used.Furthermore, this known device enables only one roll for the upper plyto be replaced, while the one for the opposing ply cannot be replacedautomatically. In some cases, it is useful to modify only the embossingpattern of one ply, while keeping the embossing pattern of the opposingply fixed. This is particularly true, for example, in the production ofdouble-sided materials where one of the outer plies is micro-embossed,with a pattern that remains always the same, while the other outer plyis embossed with a decorative motif, which can vary according to theprocessing order. But in some other cases it is necessary to change bothrolls, like in the case of switching from a towel roll product to atoilet roll product, or in the case of switching rolls between similarconverting lines. With the device described in EP1074382, it istherefore necessary to have more rolls, which increases the overallcosts, or is necessary to use conventional manual devices, like a crane,to remove all the rolls from the machine, resulting in longer rollchange time.

EP1836045 discloses an embossing-laminating device with interchangeableembossing rolls that is improved with respect to the device disclosed inEP1074382. In fact, the device disclosed in EP1836045 makes it possibleto have a plurality of pairs of embossing rolls in a magazine and toselect one or other of said pairs, inserting them in theembossing-laminating device. This means that it is no longer necessary,as is the case with EP1074382, to have all the embossing rolls fittedwith the machine supported by the same star unit. This makes it possibleto simplify and lighten the embossing device while at the same timehaving available a large number of pairs of alternative rolls, in muchlarger quantities than those permitted by EP1074382.

U.S. Pat. No. 7,584,698B2 describes a method of mounting and accessingrolls that improves access to the roll, but in a less ergonomic andautomated way than is described herein. While removal with a crane iseased, access to the roll for personnel performing the change is not,making for an inefficient roll change.

US20030075263A1 discloses a corrugator device capable of a quickchangeover between two corrugating rolls so that one roll or the othercan be positioned in working position while the other remains into themachine. The limitation in this case is the fact that if one of therolls inside the machine has to be changed for maintenance or productchange, the change time is increased.

WO2015/150452A1 describes a laminator with an automated change processthat places the steel embossing rolls in a magazine mounted beneath thelaminator where they are stored while not in use. There are numerousissues with this approach including inability to clean and maintain therolls, a limited number of rolls that can be automatically changed, andthe inability to share rolls between other embosser/laminators withinthe same manufacturing facility.

U.S. Pat. No. 9,193,127B2 describes a roll changing device that operateson a pair of rolls and manages the selection of the rolls within themain machine. This method has a drawback in that the number ofinterchangeable rolls dictates the size of the machine. A small machinefootprint is critical to many operators of this equipment so anadditional space requirement is seen as negative. A further drawback isthat more complex equipment is required to be onboard the main machineto change the roll sets than described herein, affecting access foroperability and maintainability of the machine.

To ease roll change many embosser/laminators use a belt driven maintransmission in a way that the steel embossing roll is not captured bythe belt. Many also couple multiple embossing rolls together with abelted transmission. This allows for easier access to the roll forchanging but it has technical drawbacks. Belt transmissions areinherently more compliant than geared transmissions. More transmissioncompliance means that the load is not driven accurately which can leadto misalignment when doing certain multiple-ply operations where manyembossing rolls are rotated synchronously, known by experts in the fieldas “nested” or “DESL”. By coupling the drive motor directly to the load,more accurate feedback is achieved and if errors arise they can becorrected quickly by the machine's control system.

All of these known systems are designed to speed the roll changingprocess and in many cases increase the level of safety in doing so. Theyall require the additional expense of built-in equipment to manage theroll change process. This additional expense limits its availability tothe market. Only those operators whose budget allows for this extraexpense can benefit from the improvements of these known devices. Therest of the market is left with changing rolls using cranes that mayhave difficult access points and lifting requirements. These drawbacksof the prior art are addressed in the description that follows below.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial, perspective view of an adhesive unit engaged inline with a main frame structure of an embosser/laminator machine.

FIG. 2 is a partial side view of the adhesive unit engaged in line withthe main frame structure of the embosser/laminator machine.

FIG. 3 is a partial, perspective view of the adhesive unit disengagedfrom the main frame structure of the embosser/laminator machine andshowing the bearing caps withdrawn from the rolls of theembosser/laminator machine.

FIG. 4 is a partial side view of the adhesive unit disengaged from themain frame structure of the embosser/laminator machine and showing thebearing caps withdrawn from the rolls of the embosser/laminator machine.

FIG. 5 is a partial, perspective view showing a first embodiment of acart maneuvered into position in a space between the disengaged adhesiveunit and the main frame structure of the embosser/laminator machine.

FIG. 6 is a partial side view showing the first embodiment of the cartmaneuvered into position in the space between the disengaged adhesiveunit and the main frame structure of the embosser/laminator machine.

FIG. 7 is a partial, perspective view showing a second embodiment of thecart maneuvered into position in the space between the disengagedadhesive unit and the main frame structure of the embosser/laminatormachine.

FIG. 8 is a partial side view showing the second embodiment of the cartmaneuvered into position in the space between the disengaged adhesiveunit and the main frame structure of the embosser/laminator machine.

FIG. 9 is a partial, perspective view showing the first embodiment ofthe cart in register with the main frame structure of theembosser/laminator machine, and the upper roll engaged with an endeffector of the extractor driving the upper roll to a position where theroll may be removed from the machine with a crane.

FIG. 10 is a partial, side view showing the first embodiment of the cartin register with the main frame structure of the embosser/laminatormachine, and the upper roll engaged with the end effector of theextractor driving the upper roll to a position where the roll may beremoved from the machine with a crane.

FIG. 11 is a partial side sectional view showing the upper roll engagedwith an end effector of the extractor and the crane.

FIG. 12 is a partial, perspective view showing the second embodiment ofthe cart in register with the main frame structure of theembosser/laminator machine, and the upper roll engaged with the endeffector of the extractor driving the upper roll to a position to bereceived by the second embodiment of the cart.

FIG. 13 is a partial, side view showing the second embodiment of thecart in register with the main frame structure of the embosser/laminatormachine, and the upper roll engaged with the end effector of theextractor actuator driving the upper roll to a position to be receivedby the second embodiment of the cart.

FIG. 14 is a partial, perspective view showing the first embodiment ofthe cart in register with the main frame structure of theembosser/laminator machine, and the crane lowering the upper roll ontothe cart.

FIG. 15 is a partial, side view showing the first embodiment of the cartin register with the main frame structure of the embosser/laminatormachine, and the crane lowering the upper roll onto the cart.

FIG. 16 is a partial, perspective view showing the second embodiment ofthe cart in register with the main frame structure of theembosser/laminator machine, and a deck of the cart lowering the upperroll to a retracted position of the deck of the cart before removal fromthe line.

FIG. 17 is a partial, side view showing the second embodiment of thecart in register with the main frame structure of the embosser/laminatormachine, and a deck of the cart lowering the upper roll to a retractedposition of the deck of the cart before removal from the line.

FIG. 18 is a partial side view of the adhesive unit engaged with theembossing/laminating machine and showing paths of threading members usedfor threading plies of a web through the embosser/lamination machine.

FIG. 19 is an enlarged view of detail area 19-19 of FIG. 18 showing aweb holder for temporarily holding the web during stopping of themachine for roll extraction.

DETAILED DESCRIPTION

An exemplary laminating/embosser machine LEM may comprise an adhesiveunit 2 connectable to a main frame structure 3 of the LEM. The LEM mayhave an upper and lower roll 7, for instance, a steel embossing roll,and a pressure roll 8, for instance, a rubber embossing roll. Theadhesive unit 2 may be comprised of one or more sub-frames that aremovable relative to the main frame structure 3 of the LEM in thedirection of process flow between engaged and disengaged positions ofthe adhesive unit relative to the main frame structure. For instance,the adhesive unit 2 and/or its sub-frames may be mounted on rails orslides. The movement between the engaged and disengaged positions of theadhesive unit may be effectuated with actuators known in the art, forinstance, a manual operator, or a hydraulic, pneumatic, orelectro-mechanical operator. FIGS. 1 and 2 show the adhesive unit 2connected with the main frame structure 3 of the LEM in the engagedposition. FIGS. 3 and 4 show the adhesive unit 2 spaced from with themain frame structure 3 of the LEM in the disengaged position. In thedisengaged position, the adhesive unit 2 may be released and moved awayfrom the main frame structure 3 with sufficient space to allow removalof the embossing rolls 7 or maintenance functions. When in the normaloperating or engaged position, the adhesive unit is locked into andotherwise physically connected with the main frame structure to securethe embossing rolls 7.

The adhesive deck 2 and the main frame structure 3 of the LEM may eachhave a portion of bearing housing BH for the rolls of the LEM. Theportion of the bearing housing BH associated with the adhesive unit 2(e.g., the bearing cap 9) and the portion of bearing housing BHassociated with the main frame structure 3 may cooperate together toform the bearing housing when the adhesive unit 2 is in the engagedposition. When the adhesive unit 2 is in the disengaged positionrelative to the main frame structure 3, the bearing cap 9 associatedwith the adhesive unit is spaced from the portion of the bearing housingassociated with the main frame structure in a manner to allow the roll 7to be removed from the main frame as will be explained below. Thebearing cap 9 associated with the structure of the sub-frame(s) of theadhesive unit 2 may be monolithically formed in the frame or integrallyformed in the frame. In the engaged position, the bearing cap 9associated with the adhesive unit 2 and the portion of the bearinghousing associated with the main frame structure 3 may be lockedtogether to secure the bearings of the embossing roll under the highloads typically found in embossing operations. By way of example, thelock may be an over-center latch that is actuated by an actuatorcylinder or motor, and which is configured to remain in its latchedposition in the event of loss of energy (e.g., loss of air or hydraulicpressure or electrical power). Although the drawings show the bearingcap 9 formed on the adhesive deck and a portion of the bearing housingformed on the main frame structure, the entire bearing housing may beintegrated with adhesive deck or the main frame. For instance, amechanical lock formed on the adhesive deck/main frame may be releasedwhen the adhesive deck is moved to the disengaged position therebyreleasing the bearing cap from the bearing housing and the roll from themain frame structure.

The rolls 7,8 may be driven with a motor and gear train (not shown).When roll change-over is desired, the drive system of the roll 7 may bedisengaged, so that when the adhesive unit 2 is moved to the disengagedposition, one or more of the rolls 7 may be exposed in the LEM mainframe structure 3, disconnected from the drive, and ready for removal.In one example, the embossing roll 7 may be automaticallycoupled/uncoupled to a motorization unit. Commercially availablecouplings, such as R+W model EK6-4500-B-75-120, may be used. Thecoupling can be engaged and disengaged using an integrated clutchassembly or by displacement of the motorization unit, either of whichcan be an automated or manual operation. Automatic engagement anddisengagement of the motorization unit from the embossing roll improvesroll change over and set-up time. Further, such couplings allow forimproved alignment of the rolls. For instance, when processing multipleembossed webs with the embossed motifs synchronized, which are processesknown to experts in the field, including such processes as registerednested, DESL, point-to-point and others, it is important that theembossed motifs are aligned sufficiently. Traditionally, to start a newproduction job, the LEM will be briefly put into production while thealignment of the embossed motifs is verified. If the embossed motifs arenot properly aligned, an adjustment is made to the change the angularrelationship between the steel rolls, and the alignment is againverified until satisfactory. Using a coupling with direct connectionbetween the drive and the roll as described above minimizes thecombinations of orientations between the motor and the roll, allowingthe machine control system to automatically relate the orientation ofthe roll during disengagement and engagement of the coupling. If theroll relationship to the motor is known, the verification of embossedmotif alignment can be eliminated or simplified. This can be achieved byleveraging a previously known relationship between the motor and roll,knowing the difference of orientation between the motor encoder and rollfor all possible coupling engagements, and determining which couplingengagement was made after loading the new roll. This transmission methodis also preferred over a conventional belt transmission because betterperformance can be achieved as a result of a more rigid connectionbetween the motor and the roll. As rigidity of the coupling betweenmotor and roll increases so does controllability of the roll.

The LEM main frame 3 may be provided with an extractor 10 to move eachof the rolls between the roll normal operating position in the mainframe and an exchange position spaced from the main frame where the roll7 is accessible for removal by a cart 11 or crane 12. After normaloperation of the LEM is stopped for roll change, the extractor 10 isconfigured to hold the roll 7 in place after the bearing caps 9 areunlocked. The extractor 10 may comprise an actuator 13, for instance, ascrew jack actuator provided by Joyce model WJ1000U4S-29-STDX-STDX-X, ora similar type of actuator known in the art capable of moving the rollbetween the operating position and the exchange position. The extractor10 may further comprise an end effector 14 that engages the axial endsof the roll. The end effector 14 may have any configuration necessary toengage the roll and secure it in place while the actuator 13 moves theroll between the operating position and the exchange position. The endeffector 14 may also have any configuration necessary to hold the roll 7in position when the adhesive unit is moved to the disengaged position.The end effector 14 may also engage surfaces on the axial ends of theroll used to rotate and drive the roll during normal operations of themachine. The end effector 14 may also engage the operating surface ofthe roll. The end effector 14 can be advantageously shaped in order totransport the roll with repeatability to the desired pick up positionfor the crane or cart. The end effector 14 can also be advantageouslyshaped to work with collars present on the roll journals, so that theroll can always be positioned correctly relatively to its axialdirection and main machine frames.

As shown in FIG. 9-13, the extractor 10 projects outward from the mainframe structure 3 of the LEM allowing the roll to be positionedsufficiently away from the LEM main frame to allow access by the crane12 or the cart 11,11′. The roll handling cart 11′ may be placed inregister with the LEM main frame structure 3 and the roll 7 to changethe roll (See FIGS. 7-8 and 12-13). Alternatively, the roll 7 could beplaced on the cart 11 using a crane 12 (See FIGS. 5-6, 9-11, and 14-15).

The cart 11,11′ allows the roll 7 to be easily made available for use inthe LEM, for maintenance or cleaning, or for transportation in, around,and out of a facility. In one embodiment of the cart, the cart 11′ maybe configured with a lift mechanism 15 providing a deck 16 of the cartwith an adjustable height with a range of travel to allow the ability tochange rolls in either the upper or lower position on the main framestructure 3 of the LEM, and facilitate manual or automatic maintenanceand cleaning of the rolls. The deck 16 of the cart may be raiseddirectly to the exchange position of any embossing roll 7 to receive theroll from the extractor 10 and to be lowered as necessary without anadditional device such as a crane. Alternatively, the roll 7 may beplaced on a cart using a scissor lift built-into the decking between themain frame structure 3 and the sub-frame 2. The scissor lift may movebetween a lowered position in which the scissor lift platform issubstantially flush with decking between the main frame structure 3 andthe sub-frame 2, and a raised position in which the scissor liftplatform is in register with the extractor 10 of an associated roll 7.The scissor lift platform may move between the raised and loweredposition within an open framework formed internal to the cart, or aroundthe outer periphery or structure of the cart.

The cart 11,11′ may have roll fastenings that cooperate with the roll orits bearing housings. As the roll is brought into register with thecart, it can be moved seamlessly into the roll fastenings. The cart rollfastenings may secure the roll onto the cart. To facilitate the seamlesstransfer, the cart roll fastenings may have a geometry that complementsand/or interlocks with the roll, for instance, the axial end drive orbearings of the roll. The cart roll fastenings may also have a geometrythat complements and/or interlocks with the extractor to allow a rigidconnection between the main frame structure 3, and the cart 11′ as theroll 7 is moved between the main frame structure and the cart in casethe cart is equipped with an adjustable height deck 16. For instance,rails (not shown) may be placed between the roll fastenings and the mainframe structure, and the roll 7 may translate on the rails from the LEMmain frame structure to the cart roll fastenings, at which point theroll may be secured to the cart. In one embodiment, the cart rollfastenings may have a geometry similar to the end effector 14 of theextractor 10. In order to transfer the roll from the extractor to thecart roll fastenings, the deck 16 of the cart 11′ may be moved(vertically upward in the drawings) a distance to lift the roll usingthe cart roll fastenings out of the extractor end effector 14. Theextractor 10 may then be moved to the operating position so the endeffector 14 is clear of the roll. The deck 16 of the cart 11′ may thenbe lowered with roll secured in the cart roll fastenings. Depending uponembodiment, the platform of the scissor lift may be similarly configuredwith roll fastenings.

When using the crane 12 to remove the roll 7 from the end effector 14,the crane may be moved (vertically upward in the drawings) until theroll clears the end effector, at which point the extractor 10 may bemoved to the operating position providing clearance for the crane tomove the roll, for instance, to a storage facility or onto the cart 11as shown in FIGS. 9-11 and 14-15.

The extractor 10 may be a part of an automated process where an operatorremote to the LEM operates the extractor 10, crane 12, and/or cart 11remotely. This decreases operator exposure to the line and equipment.Further, to the extent a cart is not used, the extractor 10 may move theroll 7 away from the LEM main frame structure 3 to a position where aconventional crane 12 can more easily access the roll. The crane 12could be arranged on-board or integral with the LEM for the specificpurpose of changing the rolls or it could be a more general maintenanceor a facility general purpose crane.

Making reference to the drawings, one process for removing a roll fromthe LEM is as follows: (i) the machine stops and the machine operatorinitiates the roll change sequence; (ii) motorization of the embossingroll is uncoupled automatically; (iii) the bearing caps are unlocked;(iv) the adhesive unit/sub-frame 2 is moved to the disengaged positionand the bearing cap on the adhesive unit is spaced away from the portionof the bearing housing on the LEM main frame structure 3 (see FIGS.3,4); (v) the empty cart 11 enters the space created between the LEMmain frame structure 3 and the adhesive unit 2 (see FIGS. 5,6); (vi) theextractor 10 moves the desired roll 7 to the exchange position (seeFIGS. 9,10); (vii) the crane 12 lowers the roll 7 to the cart 11 (seeFIGS. 11, 14, 15); and (viii) the cart 11 exits the LEM loaded with theroll 7.

Making reference to the drawings, another process for removing a rollfrom the LEM is as follows: (i) the machine stops and the machineoperator initiates the roll change sequence; (ii) motorization of theembossing roll is uncoupled automatically; (iii) the bearing caps areunlocked; (iv) the adhesive unit/sub-frame 2 is moved to the disengagedposition and the bearing cap on the adhesive unit is spaced away fromthe portion of the bearing housing on the LEM main frame structure 3(see FIGS. 3,4); (v) the empty cart 11 enters the space created betweenthe LEM main frame 3 and adhesive unit and a deck 15 of the cart ispositioned in register with the extractor (see FIGS. 7,8); (vi) theextractor 10 moves the desired roll 7 to the exchange position (seeFIGS. 12,13); (vii) the deck 15 of the cart is lowered with the roll 7(see FIGS. 16,17); and (viii) the cart 11 exits the LEM loaded with theroll 7.

Following roll removal, the process for installing a roll in the machineis achieved by performing the removal steps in reverse as describedbelow. For instance, a process involving the cart 11 and the crane 12may be as follows: (i) a roll is introduced to the machine with a secondcart; (ii) the crane raises the roll from the cart to the extractor;(iii) the extractor moves the roll into operating position in the LEMmain frame structure 3; (iv) the now empty second cart leaves the LEM;(v) the adhesive unit/sub-frame is moved to the engaged position (seeFIGS. 1,2); (vi) the bearing caps 9 are locked into the LEM main framestructure 3 to form the bearing housings; (vii) motorization of theembossing roll is recoupled; and (viii) the machine is returned toproduction.

As another example, a process involving only the cart is as follows: (i)a new roll is introduced with a second cart; (ii) the deck 15 of thecart 11 is raised to bring the roll 7 to the extractor 10; (iii) theextractor moves the roll into operating position in the LEM main framestructure 3; (iv) the now empty second cart leaves the LEM; (v) theadhesive unit/sub-frame is moved to the engaged position (see FIGS.1,2); (vi) the bearing caps 9 are locked into the LEM main framestructure 3 to form the bearing housings; (vii) motorization of theembossing roll is recoupled; and (viii) the machine is returned toproduction.

After the roll is lowered to the deck of the cart 11,11′, the cart androll may be moved out of the LEM where it can be cleaned and put intostorage. The roll may be stored on or off the cart, for instance, in aroll storage rack. If desired there may be only enough carts to performthe roll changing process. In this case, the rolls are taken off thecart before being put into storage. Others may choose to dedicate a cartto a particular roll, for moving it around their facility, and forstorage of the roll. The next time the roll is needed, for instance, forthe same machine or machine using an equivalent roll, the roll may beretrieved from the storage rack, placed on the cart and rolled out tothe LEM, or if the roll is already stored on a dedicated cart, the rollmay be rolled out to the LEM on the cart.

The process of changing between embossed motifs can be further automatedby incorporating radio frequency identification (RFID) technology. Eachroll may be fitted with an RFID tag. The RFID tag could communicate tothe embosser/laminator machine the aforementioned roll alignmentinformation, along with embosser/laminator machine setup adjustmentinformation which otherwise must be entered by a machine operator.

To facilitate changing between embossing motifs within anembosser/laminator or between more than one embosser/laminator, one ormore roll storage magazines can be located convenient to the machine(s)that make use of the rolls stored therein. Such roll storage magazinescan be fitted with roll extractors and split bearing caps similar tothose located within the embosser/laminator, to facilitate transferringrolls between the LEM and the storage magazine.

To facilitate rethreading of the LEM, the LEM may be fitted with a webholder 21 (see FIGS. 18-19) that temporarily holds one or more plies 20of the web in place until a new roll is installed. Ordinarily, theprocess of extracting and changing the roll will typically involvesevering the ply of web material 20 to be embossed with that roll. Ifthe ply of web material 20 is not held in place once severed, it can bedrawn back through the LEM and upstream machines, which increases therethreading time and therefore the time to return the machine tooperation. The web holder 20 may include an actuator 22 that may bemoveable between an engaged position and a disengaged position. In theengaged position, the actuator may drive a stop 23 to a position wherethe stop presses the web 20 against a surface 24 such that the plies 21of the web are held in place between the stop and the surface. In thedisengaged position, the actuator 22 may position the stop 23 at adistance from the surface 24 where the web 20 passes freelytherebetween. In one example, as shown in the drawings, the stop 23 maypivot (e.g., counterclockwise) to a position where it presses the web 20against the surface 24. Alternatively, the stop may move linearly to aposition where it presses the web against the surface. The stop andsurface may both move toward each other through one or more actuators tothe engaged position and away from each other to the disengagedposition. The surface may be a structure of the LEM and stationaryrelative to the sub-frame.

Additionally, to facilitate rethreading of the LEM, the LEM may befitted with multiple threading members that collectively form points ofdiscontinuity adjacent to nip points in the LEM, thereby eliminating theneed to disconnect the threading member before roll change and toreconnect the threading member after roll change. Prior to roll change,the LEM and its associated machines upstream may be adapted andconfigured to pay out a sufficient length of the ply of web material 20for an operator to connect with the threading member. The threadingmember may be a belt, rope, or similar long and flexible member intowhich the free end of the ply of web material 20 is inserted, and whichis then manually or automatically moved through the machine until theply of web material reaches the last machine in the web convertingprocess. The threading member may be a continuous loop driven by a motorand directed along its path through various points around the LEM withpulleys and guide rollers. Depending upon its location in the LEM, thethreading member may be contained with the frame members of the LEM oroutside of the frame members of the LEM. In one example, a first inboundthreading member 30 may be adapted and configured to draw a ply from afirst supply 32 to a position adjacent to the nip point 34 of the topembossing roll 7 and top pressure roll 8 before returning to a positionadjacent the first supply, and an exit threading member 36 may beadapted and configured to draw the ply from a point adjacent to the nippoint 34 of the embossing roll 7 and pressure roll 8 to a positionadjacent downstream machinery 38. The first and second points arearranged in the main frame structure in a manner such that the first andsecond threading members have sufficient clearance with the roll in themain frame structure of the machine to allow removal and installation ofthe roll in the main frame structure of the machine without alterationof the first and second threading members, for instance, removing thethreading members from the LEM. By routing the first inbound threadingmember 30 and the exit threading member 36 adjacent to each other andadjacent to the nip point 34 of the embossing roll 7 and pressure roll 8with sufficient clearance with the embossing roll, the embossing rollmay be removed and reinstalled in the LEM without interference fromeither threading member 30,36. This arrangement eliminates issues withdesigns using one threading member extending from the nip point andwrapped around the embossing roll, which require the threading member tobe disconnected prior to roll change. Because the first inboundthreading member 30 and the exit threading member 36 are adjacent toeach other and adjacent to the nip point 34 of the embossing roll 7 andpressure roll 8, neither threading member wraps around the embossingroll and thus neither threading member needs to be removed andreinstalled during roll change. Further, during roll exchange when thesub-frame is moved to the disengaged position, the ply of the web may beaccessed without interference from the threading member 30,36.

By way of example, FIG. 18 shows an example of 4 threading membersassociated with the LEM. The first inbound threading member 30 may drawthe ply from the first supply 32 to the nip point 34 adjacent the toppressure roll 8 and top embossing roll 7. A second inbound threadingmember 40 may draw a ply from a second supply 42 to a nip point 44adjacent the bottom pressure roll 8 and bottom embossing roll 7. Thethird inbound threading member 50 may draw a ply from a third supply 52to the nip point 34 adjacent the top pressure roll and top embossingroll. The exit threading member 36 may draw a ply from a positionadjacent to the nip 34 of the top pressure roll and top embossing roll,a ply from a position adjacent to the nip 44 of the bottom pressure rolland bottom embossing roll, and/or plies from both positions dependingupon the configuration of the LEM and the product being processed. Withthe sub-frame 2 in the disengaged position, the ply from the firstinbound threading member 30 and the ply from the second inboundthreading member 40 may be accessed at the nip point 34 of both the toppressure roll and top embossing roll and the nip point 44 of the bottompressure roll and bottom embossing roll, and connected with the exitthreading member 36 to be directed to downstream machinery 38. In a likemanner, depending upon the product and machine configuration, the plyfrom the third inbound threading member 50 may be accessed at the nip 34of the top pressure roll and top embossing roll and connected with theexit threading member 36 to be directed to downstream machinery 38.Again, depending upon the product and machine configuration, the plyfrom the third inbound threading member 50 may be accessed at the nip 34of the top pressure roll and top embossing roll, and the ply from thesecond inbound threading member may be accessed at the nip 44 of thebottom pressure roll and bottom embossing roll, and connected with theexit threading member 36 to be directed to downstream machinery 38.Other combinations of gathering the plies at one or both of the nips mayalso be achieved depending upon the configuration of the LEM and theproduct being processed. With the sub-frame moved to the disengagedposition during top and/or bottom embossing roll exchange, the ply ofthe web may be accessed without interference from the threading member30,36,40,50, thereby simplifying roll exchange and threading procedures.

As is apparent from the foregoing description and drawings, the rolls7,8 may be arranged in the LEM in a manner that is beneficial to theembossing/laminating process, but also advantageous to roll removal. Forinstance, the rolls may be positioned in the LEM in a manner such thatany deflection resulting from the various nip loads applied to the rolland load from the weight of the roll is minimized. The rolls can bepositioned in the LEM such that the web enters the embossing nip at aposition tangent or nearly tangent to the nip with no wrap or minimalwrap angle around the roll. The rolls can be positioned in the LEM suchthat the free span of one web of material prior to joining with theother web of material is minimized. Additionally, the rolls can bepositioned in the LEM such that the length of the joined plies of theweb material prior to the final setting of the lamination with pressure,adhesive, or other means is minimized.

The LEM as described herein may be modified with certain manualfunctions. For example, the LEM may include bearing caps that areseparate members which are not integrally formed with the sub-frame ofthe adhesive unit 2. In one example, the sub-frames of the adhesive unit2 may be moved longitudinally away from the main frame structure 3 ofthe LEM to create space for the roll exchange. An operator may thenmanually remove the bearing caps from the main frame structure 3 and/orthe adhesive 2 unit to allow transfer of the roll to the cart. Thepressure or rubber roll 8 may have a system of bearing caps that may beopened, for instance, in a manner similar to the embossing roll 7. Anextractor of the type previously described for the embossing roll may beprovided adjacent to the pressure roll 8 allowing the pressure roll tobe moved into and out of the LEM in a manner similar to that ofembossing roll, including through use of the cart 11,11′, crane 12 andor deck mounted scissor lift. In addition, other rolls associated withLEM (e.g., a marrying roll, applicator roll or gravure roll) may eachhave an extractor allowing the roll to be moved into and out of the LEMin a manner similar to that of embossing roll, including through use ofthe cart 11,11′, crane 12 and or deck mounted scissor lift.Additionally, instead of the actuator 13, the extractor 10 may beequipped with a hand wheel or lever that an operator may use to manuallymove the roll to the exchange position. Rather than an on-boardautomated crane and/or cart with an adjustable height deck, a generalpurpose facility maintenance crane can remove the roll from the machine.The extractor, adhesive unit bearing caps, and/or cart, as describedherein, may be retrofitted to an existing embosser/laminator machine toincrease the operational flexibility of the machine.

It should also be understood that when introducing elements of thepresent invention in the claims or in the above description of exemplaryembodiments of the invention, the terms “comprising,” “including,” and“having” are intended to be open-ended and mean that there may beadditional elements other than the listed elements. Additionally, theterm “portion” should be construed as meaning some or all of the item orelement that it qualifies. Moreover, use of identifiers such as first,second, and third should not be construed in a manner imposing anyrelative position or time sequence between limitations. Still further,the order in which the steps of any method claim that follows arepresented should not be construed in a manner limiting the order inwhich such steps must be performed, unless such an order is inherent.

As various modifications could be made in the constructions and methodsherein described and illustrated without departing from the scope of theinvention, it is intended that all matter contained in the foregoingdescription or shown in the accompanying drawings shall be interpretedas illustrative rather than limiting. Thus, the breadth and scope of thepresent invention should not be limited by any of the above-describedexemplary embodiments, but should be defined only in accordance with thefollowing claims appended hereto and their equivalents.

What is claimed is:
 1. A method comprising: accessing a machine forprocessing a web of material wherein the machine has a main framestructure, a sub-frame releasably connectable with the main framestructure, and an extractor operatively connected with the main framestructure adapted and configured to move a roll of the machine betweenthe main frame structure and an exchange position between the main framestructure and the sub-frame when the sub-frame is released from the mainframe structure; disconnecting the sub-frame from main frame structure;moving the sub-frame from the main frame structure; and moving theextractor to the exchange position between the moved away sub-frame andthe main frame structure.
 2. The method of claim 1 wherein the step ofmoving the extractor to the exchange position includes moving the rollof the machine from the main frame structure to the exchange position.3. The method of claim 2, further comprising removing the roll from theextractor with a crane with the extractor in the exchange position. 4.The method of claim 3 wherein the step of removing the roll from theextractor with the crane with the extractor in the exchange positioncomprises using a crane operatively mounted on the machine.
 5. Themethod of claim 4, wherein the step of placing the roll on the cartcomprises elevating a deck to a position to engage the roll from theextractor with the extractor in the exchange position.
 6. The method ofclaim 3, wherein the step of removing the roll from the extractor withthe crane with the extractor in the exchange position comprises usingthe crane to transport the roll to a storage location.
 7. The method ofclaim 5 further comprising using the cart to transport the roll to astorage location.
 8. The method of claim 5, wherein the step of placingthe roll on the cart comprises elevating a deck to a position to engagethe roll from the extractor with the extractor in the exchange position.9. The method of claim 1 further comprising: (i) placing a roll on theextractor after performing the step of moving the extractor to theexchange position, (ii) moving the roll from the exchange position tothe main frame structure; (iii) moving the sub-frame toward the mainframe structure; (iv) connecting the sub-frame with main framestructure; and (v) operatively securing the roll to the machine betweenthe sub-frame and the main frame structure.
 10. The method of claim 9,further comprising placing the roll on the extractor with a crane withthe extractor in the exchange position.
 11. The method of claim 9,further comprising placing the roll on a cart, and arranging the cartbetween the spaced apart sub-frame and the main frame structure.
 12. Themethod of claim 11, further comprising elevating a deck to a position toengage the roll with the extractor in the exchange position.
 13. Themethod of claim 1 further comprising holding a position of web relativeto the main frame structure prior to disconnecting the sub-frame frommain frame structure.
 14. A method comprising: accessing a machine forprocessing a web of material wherein the machine has a main framestructure and an extractor operatively connected with the main framestructure, the extractor is adapted and configured to reciprocate in ahorizontal direction into and out of the main frame structure; movingthe extractor horizontally out of the main frame structure to anexchange position spaced from the main frame structure; and performingone of (i) receiving a roll onto the extractor for installation in themachine, and (ii) moving a roll of the machine from the main framestructure to the exchange position for removal of the roll from machine;wherein the machine further comprises a sub-frame configured and adaptedto be moveable relative to the main frame structure; and the methodfurther comprises: disconnecting the sub-frame from the main framestructure; and moving the sub-frame away from the main frame structurebefore the step of moving the extractor to the exchange position. 15.The method of claim 14 further comprising moving a roll of the machinefrom the main frame structure to an exchange position between the mainframe structure and the sub-frame.
 16. The method of claim 15 whereinthe step of disconnecting the sub-frame from main frame structureincludes releasing the roll from a bearing housing formed by a portionof the main frame structure and a portion of the sub-frame.
 17. Themethod of claim 14 further comprising receiving a roll of the machine onthe extractor with the extractor in an exchange position between themain frame structure and the sub-frame.
 18. The method of claim 17further comprising moving the extractor from the exchange position to anormal operating position within the machine and securing the roll tothe machine between the sub-frame and the main frame structure.
 19. Themethod of claim 18 wherein the step of securing the roll to the machinebetween the sub-frame and the main frame structure includes installingthe roll in a bearing housing formed by a portion of the main framestructure and a portion of the sub-frame.